Digital mask-image-projection-based additive manufacturing that applies shearing force to detach each added layer

1. A system for producing a three-dimensional object in cascaded layers from a liquid resin that solidifies upon exposure to light, the system comprising:

a vat that has a configuration that holds the liquid resin, the vat having a transparent bottom that allows light to pass through the transparent bottom and into the liquid resin;

a mask image projection system that projects a controllable two-dimensional image through the transparent bottom of the vat and into the liquid resin that causes a portion of the liquid resin to solidify in the shape of the two-dimensional image;

a translation stage; and

a process controller that has a configuration that, during use of the system:

causes the translation stage to be in a position relative to the vat that is suitable for solidifying the highest layer of the three-dimensional object that has not yet been solidified directly beneath any existing layers of the three-dimensional object that have been solidified;

causes the mask image projection system to project a two-dimensional image of the highest un-solidified layer of the three-dimensional object through the transparent bottom of the vat and onto the liquid resin, thereby causing a portion of the liquid resin to solidify in the shape of the two-dimensional image and to adhere to the bottom of a surface beneath the solidified layer and to the bottom of the last layer that was previously solidified or, if none, to the bottom of the translation stage;

causes a shearing force to be applied between the bottom surface of the solidified layer and the surface beneath that is great enough to detach the solidified layer from the surface beneath it; and

causes the foregoing sequence of steps to be repeated until all of the cascaded layers of the three-dimensional object are solidified.

2. The system for producing a three-dimensional object in cascaded layers of claim 1 wherein the process controller has a configuration that causes the shearing force to be applied between the bottom surface of the solidified layer and the surface beneath that is great enough to detach the solidified layer from the surface beneath by causing relative horizontal, longitudinal movement between the translation stage and the vat.

3. The system for producing a three-dimensional object in cascaded layers of claim 2 wherein the process controller has a configuration that causes:

before one instance of the relative movement, the translation stage to be in a first horizontal position with respect to the vat;

after the one instance of the relative movement, the translation stage to be in a second horizontal position with respect to the vat that is substantially different than the horizontal first position; and

while in both the first and the second horizontal positions, the mask image projection system to project a two-dimensional image of the highest un-solidified layer of the three-dimensional object through the transparent bottom of the vat and into the liquid resin, thereby causing a portion of the liquid resin to solidify in the shape of the two-dimensional image.

4. The system for producing a three-dimensional object in cascaded layers of claim 3 wherein the process controller has a configuration that causes the horizontal location of the image that is projected by the mask image projection system with respect to the horizontal location of the translation stage before the one instance of the relative movement and after the one instance of the relative movement to be the same.

5. The system for producing a three-dimensional object in cascaded layers of claim 1 wherein the process controller has a configuration that causes the shearing force to be applied between the bottom surface of the solidified layer and the surface beneath that is great enough to detach the solidified layer from the surface beneath by causing the relative movement between the translation stage and the vat that applies the shearing force to be rotational movement.

6. The system for producing a three-dimensional object in cascaded layers of claim 1 further comprising a solid, transparent coating between the top of the transparent bottom of the vat and the liquid resin.

7. The system for producing a three-dimensional object in cascaded layers of claim 6 wherein the solid, transparent coating is a PDMS film.

8. The system for producing a three-dimensional object in cascaded layers of claim 7 wherein the PDMS film is coated on at least a portion of the top of the transparent bottom of the vat.

9. The system for producing a three-dimensional object in cascaded layers of claim 6 wherein the solid, transparent coating has a thickness of between 0.1 and 5 mm.

10. The system for producing a three-dimensional object in cascaded layers of claim 6 wherein the solid, transparent coating has a thickness of between 0.25 and 3 mm.

11. The system for producing a three-dimensional object in cascaded layers of claim 6 wherein the solid, transparent coating has a thickness of between 0.5 and 1.5 mm.

12. The system for producing a three-dimensional object in cascaded layers of claim 6 wherein:

the three-dimensional object has a maximum horizontal object width along its height;

the interior of the vat has a horizontal vat width that is at least twice the maximum horizontal object width; and

the transparent coating has a horizontal coating width that is no more than the horizontal vat width, less the maximum horizontal object width.

13. The system for producing a three-dimensional object in cascaded layers of claim 12 wherein the process controller has a configuration that causes the shearing force to be applied between the bottom surface of the solidified layer and the surface beneath that is great enough to detach the solidified layer from the surface beneath by causing the relative movement between the translation stage and the vat that applies the shearing force to be horizontal, longitudinal movement, and by causing the horizontal, longitudinal movement to traverse a length that is at least the maximum horizontal object width.

14. The system for producing a three-dimensional object in cascaded layers of claim 1 wherein:

the translation stage controllable moves to different locations within the vat; and

the process controller is configured to cause the relative movement between the translation stage and the vat by causing the translation stage to move.

15. The system for producing a three-dimensional object in cascaded layers of claim 1 wherein the process controller is configured to controllably move the translation stage.

16. The system for producing a three-dimensional object in cascaded layers of claim 1 wherein the process controller is configured to controllably move the vat.

17. A system for producing a three-dimensional object in cascaded layers from a first and a different second liquid resin that each solidify upon exposure to light, the system comprising:

a first vat that has a configuration that holds the first liquid resin, the first vat including a first transparent bottom that allows light to pass through the first transparent bottom and into the first liquid resin;

a second vat that is different than the first vat and that has a configuration that holds the second liquid resin, the second vat including a second transparent bottom that allows light to pass through the second transparent bottom and into the second liquid resin;

a mask image projection system that projects a controllable two-dimensional image:

through the bottom of the first vat and into the first liquid resin that causes at least a portion of the first liquid resin to solidify in the shape of the two-dimensional image; and, at a different time,

through the bottom of the second vat and into the second liquid resin that causes at least a portion of the second liquid resin to solidify in the shape of the two-dimensional image;

a translation stage; and

a process controller that has a configuration that, during use of the system:

causes the translation stage to be in a position relative to the first vat that is suitable for solidifying the highest un-solidified layer of the three-dimensional object that has not yet been solidified directly beneath any existing layers of the three-dimensional object that have been solidified;

causes the mask image projection system to project a two-dimensional image of an un-solidified layer of the three-dimensional object through the bottom of the first vat and into the first liquid resin, thereby causing at least a portion of the first liquid resin to solidify in the shape of the two-dimensional image and to adhere to the bottom of a surface beneath the solidified layer and to the bottom of the last layer that was previously solidified or, if none, to the bottom of the translation stage;

applies a shearing force between the bottom surface of the solidified layer and the surface beneath that is great enough to detach the first solidified layer from the surface beneath it;

causes the translation stage to be in a position relative to the second vat that is suitable for solidifying the highest un-solidified layer of the three-dimensional object that has not yet been solidified directly beneath any existing layers of the three-dimensional object that have been solidified;

causes the mask image projection system to project another two-dimensional image of the highest un-solidified layer of the three-dimensional object through the bottom of the second vat and into the second liquid resin, thereby causing at least a portion of the second liquid resin to solidify in the shape of the other two-dimensional image and to adhere to the bottom of a surface beneath the solidified layer and to the bottom of the last layer that was previously solidified or, if none, to the bottom of the translation stage; and

causes the foregoing sequence of steps to be repeated in connection with the first and/or second vat until all of the cascaded layers of the three-dimensional object are solidified.

18. The system of claim 17 further comprising a rotating table containing the first and the second vats and that, during the sequence of steps, rotates them under the control of the process controller relative to the translation stage and the mask imaging system.

19. The system of claim 18 further comprising a first and a second brush on the rotating table and wherein the process controller has a configuration that causes:

the bottom of any cascaded layers to be brushed by the first brush but not the second brush before causing the translation stage to be in the position relative to the first vat; and

the bottom of any cascaded layers to be brushed by the second brush but not the first brush before causing the translation stage to be in the position relative to the second vat.